Method of making a housing with integral gasket components for a rearview mirror actuator assembly

This is a divisional application of application Ser. No. 09/520,868, filed Mar. 7, 2000, now U.S. Pat. No. 6,362,548 which is a divisional application of application Ser. No. 09/333,307, filed Jun. 14, 1999, now U.S. Pat. No. 6,037,689, which is a divisional application of application Ser. No. 08/838,008, filed Apr. 14, 1997, now issued as U.S. Pat. No. 5,986,364, which are herein incorporated by reference in their entireties.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to an electrically-operated mirror actuator assembly which is used in vehicles for remote adjustment of a reflective mirror element in a rearview mirror assembly, especially an exterior rearview mirror assembly. More particularly, the present invention relates to the housing for the mirror actuator assembly in which weather seals and motor noise dampeners are integrally formed with the housing, preferably by injection molding.

Today most adjustable exterior rearview mirror assemblies include a mirror actuator assembly. The mirror actuator assembly is powered by a 12-volt supply from the vehicle or vehicle ignition system and is supported and housed in the mirror assembly casing. The actuator assembly comprises an actuator housing and one or more motors with appropriate gearing, which are supported in the actuator housing. Conventional actuator housings typically include upper and lower housing members, with the actuator motor and gearing supported in the lower housing member. The actuator motor drives the gearing, which in turn drives a positioning member. During operation, actuator motors tend to generate noise that can be heard by the operator and passengers of the vehicle. Since the trend in automobile design is to reduce noise so that the operator and passengers can enjoy a peaceful ride, noise dampeners are employed to reduce the motor noise. Heretofore, these noise dampeners have been manually inserted into and affixed to the housing; therefore, their installation is labor intensive, which increases the cost of the actuator assemblies.

The positioning member of the actuator assembly is drivingly coupled to the gearing and projects through the upper housing member through openings formed in the housing to engage the back of a mirror element backing plate. The mirror backing plate is pivotally mounted to the upper housing member by a ball mount or semi-spherical structure which engages a corresponding pivot structure provided on the upper housing member of the actuator assembly. In this manner, the mirror element and mirror backing plate pivot as a unit about the pivot structure in response to the movement of the positioning member, which is driven to extend and withdraw in and out of the actuator housing by the actuator motor and gearing.

Since actuator assemblies are used in exterior rearview mirror assemblies they are exposed to numerous elements, such as rain and road spray, which could adversely affect their operation and functionality. Consequently, conventional actuators used in exterior rearview mirrors include weather seals, which are needed to seal the openings in the housing, for example, the openings in the upper housing through which the mirror positioning member extends and the connection between the upper and lower housing members. These weather seals prevent moisture and debris, which are typically encountered during use of the vehicle, from entering the actuator housing. The positioning member opening of the upper housing is typically sealed with a flexible boot. Boots typically include a first open end engaging the upper housing member over the mirror positioning member opening and a second open end engaging the positioning member wherein the second open end moves in and out of the opening in the upper housing member in response to the movement of the positioning member. These boots require manual installation and must be accurately seated on the upper housing member in order to assure proper sealing.

Conventional perimeter or gasket seals comprise a die cut gasket which is positioned between the upper and lower housing members. Die cut gaskets are labor intensive. First, the gasket cutting is subject to tight tolerance control—otherwise, there may be fit-up problems in the assembly line. Furthermore, they require careful alignment between the housing members to assure the integrity of the seal. Heretofore, all these seals have required manual insertion into the mirror actuator assembly and careful alignment in their respective openings to assure proper sealing. Hence, these seals add considerable cost to the manufacture and assembly process.

In some actuators, the gasket seal is eliminated. To eliminate the gasket seal, these actuator housings include a tongue and groove connection, with one of the upper and lower housing members including the groove, and the other member including the tongue. However to achieve the desired sealing characteristics, the tongue requires a knife edge on the perimeter of the respective housing member. These knife edge perimeters are difficult to tool and mold because the upper and lower housing members are subject to tight tolerance control—again, the need for proper fit-up in the assembly line.

Consequently, there is a need for an actuator housing that requires fewer manual steps to assemble and yet provides seals to protect the actuator housing from the elements and, optionally, dampeners to reduce the motor noise characteristics of the actuator assembly. Furthermore, there is a need for an actuator assembly that produces less noise.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides an improved actuator housing member, especially suited for use in an exterior mirror assembly that is subject to noise and exposure to numerous elements, which includes integral seals and noise dampeners that seal the actuator housing from the elements while providing dampening to the actuator motors. Additionally, the integral seal and dampeners reduce the number of manual steps in the assembly process and in the reassembly process when the actuator assembly is in need of service or repair, saving time and cost.

In one form of the invention, an upper housing member for an electrically-operated actuator assembly includes a base wall having a passage for receiving a mirror positioning member and a side wall, which connects to the base wall and extends around the perimeter of the base wall. The side wall includes at least one connector for securing the upper housing to a lower housing of the actuator assembly. A gasket material is injection molded around the passage to form an annular lip on an inner surface of the base wall and extends through the base wall to form a flexible diaphragm adjacent the outer surface of the base wall. The flexible diaphragm includes a first opening, which is injection molded to the base wall around the passage, and a second opening for receiving and sealingly engaging the positioning member, wherein portions of the flexible diaphragm which define the second opening move in and out of the passage with the positioning member when the gearing in the actuator drives the positioning member to extend out or withdraw into the actuator assembly.

In one aspect, the lip is connected to the flexible diaphragm in one or more locations. Furthermore, the base wall may include at least one aperture adjacent the passage, with the lip being connected to the flexible diaphragm through the aperture.

In another aspect, the flexible diaphragm includes a collar for engaging the positioning member, the second open end being defined by a throughbore in the collar. Preferably, the inner surface of the collar conforms to the shape of the positioning member to thereby provide increased sealing contact between the collar and the positioning member.

According to another aspect of the invention, an upper housing member for an electrically-operated actuator similarly includes a base wall having a passage for receiving a mirror positioning rod and a side wall which connects to and extends around the base wall. The side wall includes at least one connector for securing the upper housing member to a lower housing member of the actuator. Gasket material is injection molded onto the base wall to form one or more noise dampeners. The dampeners extend from the inner surface of the base wall to provide dampening to a motor supported in the lower housing member when the upper housing member is secured to the lower housing member.

In other aspects, the base wall includes a depression or groove into which the gasket material is injected. In form, the base includes a plurality of openings extending therethrough. The gasket material of the noise dampener is injection molded on the base wall over the openings so that the gasket material extends through the base wall in the openings to form leads and enlarged ends, which mechanically lock the noise dampener on the base wall of the first housing member.

According to yet another aspect of this invention, an upper housing member includes a base wall with a passage for receiving a mirror positioning member and a side wall, which connects to the base wall and extends around the perimeter of the base wall. The side wall includes a shoulder on which gasket material is injection molded to form a gasket seal for sealing the upper housing member to a lower housing member of the actuator when the upper housing member is secured to the lower housing member.

In yet another aspect, the upper housing member further includes an injection molded flexible diaphragm for sealing the passage in the base wall. In another aspect, the base wall includes one or more noise dampeners injection molded thereon.

Accordingly, the present invention provides for a simplified actuator assembly by injection molding gasket material with or onto the upper housing member, thus providing an integrally formed boot, noise dampener, and/or gasket seal in the upper housing member of the actuator assembly. The integral gasket components eliminate the need for manual insertion of the components and the need for die cutting a gasket seal and the attendant problems with positioning the gasket seal between the upper and lower housing members. Consequently, the integral seal and noise dampening components reduce material waste and labor. The seals and dampeners also reduce noise. Moreover, the integral seals and dampeners provide a modular actuator assembly that is easily serviceable.

These and other objects, advantages, purposes and features of the invention will become more apparent from a study of the following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an actuator assembly of the present invention supported in an exterior rearview mirror assembly;

FIG. 2 is a side elevational view of the actuator assembly and a mirror element and backing plate with a partial cut-away;

FIG. 3 is an exploded perspective view of the actuator assembly of FIG. 1 when inverted;

FIG. 4 is a top plan view of a cover of the actuator assembly;

FIG. 5 is a cross-sectional view taken along line V—V of FIG. 4;

FIG. 6 is a cross-sectional view taken along line VI—VI of FIG. 4;

FIG. 7 is an enlarged cross-sectional view taken along line VII—VII of FIG. 4;

FIG. 8 is a bottom plan view showing the interior of the cover of the actuator assembly including a pair of noise dampeners;

FIG. 9 is a cross-sectional view of the cover taken along line IX—IX of FIG. 8;

FIG. 10 is a cross-sectional view similar to FIG. 9 of a second embodiment of the noise dampener;

FIG. 11 is a cross-sectional view of a third embodiment of the noise dampener but taken in the direction of line XI—XI of FIG. 8;

FIG. 12 is a bottom plan view of a second embodiment of the cover of the actuator assembly illustrating the cover interior with an integral perimeter seal;

FIG. 13 is an enlarged cross-sectional view similar to FIG. 7 of a fourth embodiment of the cover;

FIG. 14 is an enlarged view of the integral perimeter seal of FIGS. 12 and 13;

FIG. 15 is an enlarged cross-sectional view taken along line XV—XV of FIG. 8 illustrating a method of mechanically locking the diaphragm to the cover;

FIG. 16 is an enlarged cross-sectional view similar to FIG. 15 illustrating a second method of mechanically locking the diaphragm to the cover; and

FIG. 17 is an enlarged cross-sectional view similar to FIG. 15 illustrating a third method of mechanically locking the diaphragm to the cover.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, the actuator assembly <b>10</b> of the present invention is shown mounted in a casing <b>11</b> of a vehicle exterior rearview mirror assembly <b>12</b>. Casing <b>11</b> houses a mirror element <b>13</b> with a backing plate <b>14</b> and actuator assembly <b>10</b>, which engages the back surface of backing plate <b>14</b> to adjust the orientation of mirror element <b>13</b> and backing plate <b>14</b>. Actuator assembly <b>10</b> adjusts the orientation of mirror element <b>13</b> through motor driven, telescoping, positioning members <b>15</b> and <b>16</b>, which push and pull on the back of backing plate <b>14</b>, as will be more fully described below.

As best seen in FIG. 2, actuator assembly <b>10</b> includes an actuator housing <b>18</b>. Actuator housing <b>18</b> preferably includes a split construction housing having a first or base housing member <b>19</b> and a second or upper housing member <b>20</b> which is secured in casing <b>11</b> by fasteners, such as screws or bolts, that extend through boss structures <b>17</b> provided on upper housing member <b>20</b>. Actuator housing <b>18</b> may also comprise a single molded member having a living hinge that divides the member into two sections, which fold to form an enclosure, for example a clam shell housing. As will be more fully explained, actuator housing <b>18</b> includes molded seals and noise dampeners. The seals and dampeners are thermoplastic elastomeric gasket material and injection molded with housing <b>18</b>. Preferably, the housing members are molded from a non-conductive material such as resinous plastic. More preferably, housing members <b>19</b> and <b>20</b> comprise a glass-filled polypropylene, which results in chemical bonding between the gasket material and the housing and aids in the adhesion between the softer gasket material and the harder, more rigid housing substrate. The seals and dampeners may be similarly mechanically bonded with housing members <b>19</b> and <b>20</b>, in which case housing members <b>19</b> and <b>20</b> are preferably a suitable thermoplastic resin, such as acrylonitrile butadiene styrenes (ABS) or polybutylene terephthalate (PBT) or other suitable melt processable resins. ABS is available under the tradename of MAGNUM from Dow Chemical of Midland, Mich.

With reference to FIGS. 2 and 3, first or base housing member <b>19</b> includes a base wall <b>21</b> and a side wall <b>22</b> that extends around the perimeter of the base wall <b>21</b> to form a base compartment <b>23</b>. Second housing member <b>20</b> similarly includes a base wall <b>24</b> and a side wall <b>25</b> that extends around the perimeter of base wall <b>24</b> to form a cover. Side wall <b>25</b> preferably includes a plurality of inverted U-shaped connectors <b>26</b> that engage corresponding tabs or detents <b>27</b> provided on the exterior of side wall <b>22</b> of base housing member <b>19</b> to releasably secure second housing member <b>20</b> to first housing member <b>19</b>. Base compartment <b>23</b> houses a pair of reversible electric motors <b>28</b> and <b>29</b> which are supported on base wall <b>21</b> of base housing member <b>19</b> and are held in place by resilient arms (not shown) that extend from the base wall <b>21</b> in a snap fit arrangement. As best seen in FIG. 3, the shafts <b>28</b><i>a </i>and <b>29</b><i>a </i>of reversible electric motors <b>28</b> and <b>29</b> include worm gears <b>30</b><i>a </i>and <b>30</b><i>b </i>for driving gearing or gear assemblies <b>32</b> and <b>34</b>, also housed and supported for rotational movement in base compartment <b>23</b>. Gear assemblies <b>32</b> and <b>34</b>, in turn, drive telescoping positioning members <b>15</b> and <b>16</b> to adjust the orientation of mirror element <b>13</b> and backing plate <b>14</b> housed in mirror assembly <b>12</b>. Preferably, motors <b>28</b>, <b>29</b> are sold under the model number FC-260RD or FK-130RH available from Mabuchi Motor, New York, N.Y.

Gear assemblies <b>32</b> and <b>34</b> are supported on and journaled in cylindrical receptacles <b>41</b> and <b>42</b> formed in first housing member <b>19</b> (FIG. <b>5</b>). Receptacles <b>41</b> and <b>42</b> include annular walls <b>43</b> and <b>44</b> which extend into annular recesses <b>46</b> and <b>48</b> formed on the bottom surfaces of the gears of gear assemblies <b>32</b> and <b>34</b> to rotatably support gear assemblies <b>32</b> and <b>34</b> in base compartment <b>23</b> (FIGS. 2, <b>3</b> and <b>7</b>). Each gear assembly <b>32</b>, <b>34</b> includes a plurality of circumferentially spaced projecting arms <b>32</b><i>a</i>, <b>34</b><i>a </i>with an internal thread <b>33</b> (FIG. 7) formed at each of their respective distal ends for engaging and meshing with threads on positioning members <b>15</b> and <b>16</b>. Each plurality of projecting arms <b>32</b><i>a</i>, <b>34</b><i>a </i>define cylindrical passages <b>32</b><i>b</i>, <b>34</b><i>b </i>therebetween which extend through the gears of gear assemblies <b>32</b> and <b>34</b>, respectively, to receive telescoping positioning members <b>15</b> and <b>16</b> (FIGS. <b>2</b> and <b>3</b>). The positioning members extend into sockets <b>50</b><i>a </i>(FIG. 2) provided on the back surface of backing plate <b>14</b> and are held against rotation by pins <b>36</b><i>b</i>, <b>38</b><i>b </i>which extend transversely through the distal ends of the respective positioning members <b>15</b> and <b>16</b>. When gear assembly <b>32</b> is driven, projecting arm <b>32</b><i>a </i>rotates with gear assembly <b>32</b> to drive non-rotational positioning member <b>15</b> to telescope in or out of passage <b>32</b><i>b</i>, depending the direction of the gear's rotation. Similarly, when gear assembly <b>34</b> is driven projecting arm <b>34</b><i>a </i>drives positioning member <b>16</b> to telescope in or out of passage <b>34</b><i>b</i>. Gear assemblies <b>32</b> and <b>34</b> are each held in place by annular walls <b>47</b><i>a </i>and <b>47</b><i>b </i>which extend from base wall <b>24</b> of upper housing member <b>20</b> and lightly engage or have end surfaces which are slightly spaced from gear assemblies <b>32</b>, <b>34</b> (FIGS. <b>7</b> and <b>13</b>). As positioning members <b>15</b>, <b>16</b> telescope in and out of passages <b>32</b><i>b</i>, <b>34</b><i>b</i>, end portions of the positioning members extend and retract through passages <b>49</b><i>a </i>and <b>49</b><i>b </i>defined by annular walls <b>47</b><i>a </i>and <b>47</b><i>b </i>provided in second housing member <b>20</b> to push and pull on the back surface <b>50</b> of backing plate <b>14</b> of mirror element <b>13</b> (FIG. <b>2</b>).

As shown in FIG. 2, second housing member <b>20</b> includes a pivot assembly <b>54</b> which cooperates with mirror backing plate <b>14</b> to fix the mirror element's point or center of rotation. Pivot assembly <b>54</b> includes a socket member <b>56</b> formed integrally on housing <b>20</b> that cooperates with a truncated, semi-spherical flange <b>57</b> formed on back surface <b>50</b> of mirror backing plate <b>14</b> (FIG. <b>2</b>). The socket member <b>56</b> includes a semi-spherical recess <b>58</b> with a central collar <b>59</b> and a semi-spherical insert <b>60</b> that is rotationally fixed to the semi-spherical recess <b>58</b> by a pivot screw <b>62</b> and pivot spring <b>64</b>. As best seen in FIG. 2, pivot screw <b>62</b> extends through pivot spring <b>64</b> and insert <b>60</b> and into a threaded boss structure <b>65</b> that projects through passage <b>65</b><i>a </i>in recess <b>58</b> (FIG. <b>3</b>). Semi-spherical flange <b>57</b> is interposed and slidably captured between insert <b>60</b> and recess <b>58</b> such that mirror backing plate <b>14</b> is free to pivot about pivot assembly <b>54</b> on semi-spherical flange <b>57</b>. When positioning member <b>15</b> extends, mirror backing plate <b>14</b> and mirror element <b>13</b> pivot on pivot structure <b>54</b> about axis W. Similarly, when pivoting member <b>16</b> extends, mirror backing plate <b>14</b> and mirror element <b>13</b> pivot on pivotal structure <b>54</b> about axis X. Note that when positioning member <b>15</b> extends or retracts, the orientation of axis W is changed but remains along plane Y. Similarly, when positioning member <b>16</b> extends or contracts, axis X moves up and down along plane Z. Consequently, the orientation of mirror element <b>13</b> can be changed to an infinite number of positions between the bounds of the fully extended and fully retracted positions of the positioning members and any combination thereof

In order to seal openings <b>49</b><i>a </i>and <b>49</b><i>b</i>, second housing member <b>20</b> includes a pair of weather sealing diaphragms or boots <b>68</b> and <b>70</b>. As previously mentioned, diaphragms <b>68</b> and <b>70</b> are preferably injection molded with the second housing member <b>20</b>. The method of molding may include insert molding or two-shot molding. Insert molding, also known as over-molding, includes the steps of first molding the second housing member <b>20</b> in a first molding apparatus and then transferring the molded second housing member <b>20</b> to a second molding apparatus in which the gasket material is molded onto the surface of the housing member <b>20</b>. On the other hand, in two-shot molding, the molding apparatus includes two injection barrels. The two-shot molding apparatus molds the second housing member in a first part of the molding apparatus and then either indexes the mold holding the molded second housing member to the next barrel to inject the gasket material or rotates the mold holding the second housing member so that the gasket material can be injected from the second barrel. The advantage of the two-shot molding process is that the molding apparatus is compact and, therefore, reduces the space requirements. Furthermore, the two-shot molding process tends to have a higher precision than the conventional insert molding. Moreover, the two-shot molding process provides significant time saving during manufacture and reduces the assembly time. A suitable two-shot molding apparatus is available from Arburg, Millington, Conn.

As best seen in FIGS. 3 and 5, diaphragms <b>68</b> and <b>70</b> comprise annular boots. Boots <b>68</b> and <b>70</b> each include an outer annular wall <b>72</b>, <b>73</b>, a flexible wall <b>74</b>, <b>75</b>, and a central sealing collar <b>76</b>, <b>77</b>, with each collar <b>76</b>, <b>77</b> including a cylindrical wall <b>80</b>, <b>82</b>. First open ends <b>68</b><i>a </i>and <b>70</b><i>a </i>of boots <b>68</b>, <b>70</b>, respectively, which are defined by the open ends of the respective outer annular walls <b>72</b>, <b>73</b>, extends around annular wall <b>47</b><i>a</i>, <b>47</b><i>b </i>of passages <b>49</b><i>a</i>, <b>49</b><i>b</i>, respectively, to thereby seal the openings formed by passages <b>49</b><i>a </i>and <b>49</b><i>b </i>through upper housing member <b>20</b>. The second open ends <b>68</b><i>b </i>and <b>70</b><i>b </i>of boots <b>68</b>, <b>70</b>, defined by the open ends of collars <b>76</b>, <b>77</b>, extend around the necks <b>15</b><i>a</i>, <b>16</b><i>a </i>of positioning members <b>15</b> and <b>16</b>, respectively, to thereby seal and engage positioning members <b>15</b> and <b>16</b>. Flexible walls <b>74</b>, <b>75</b> permit second open ends <b>68</b><i>b </i>and <b>70</b><i>b </i>to move between a retracted position within the annular walls <b>47</b><i>a </i>and <b>47</b><i>b</i>, respectively, to an extended position beyond annular walls <b>47</b><i>a </i>and <b>47</b><i>b </i>thereby maintaining a fluid tight seal between upper housing member <b>20</b> and the position members <b>15</b> and <b>16</b>.

As shown in FIG. 7, cylindrical walls <b>80</b> and <b>82</b> of collars <b>76</b> and <b>77</b> preferably include profiled inner surfaces <b>84</b> and <b>86</b>, respectively, which match the outer surface of the necks <b>15</b><i>a </i>and <b>16</b><i>a </i>of positioning members <b>15</b> and <b>16</b> to increase the contact surface and, thereby, provide an increased sealing surface on positioning members <b>15</b> and <b>16</b>. Sealing collars <b>76</b> and <b>77</b> project inwardly toward the interior of housing <b>18</b> from the inner perimeters <b>74</b><i>a </i>and <b>75</b><i>a </i>of flexible walls <b>74</b> and <b>75</b>. In this manner, as positioning members <b>15</b> and <b>16</b> extend in and out of actuator housing <b>32</b>, sealing collars <b>76</b> and <b>77</b> flex in and out of opening <b>49</b><i>a </i>and <b>49</b><i>b </i>of upper housing member <b>20</b> while fully engaged with positioning members <b>15</b> and <b>16</b> to assure a continuous seal with the positioning members <b>15</b> and <b>16</b>. As best seen in FIG. 8, diaphragms <b>68</b> and <b>70</b> also include annular lips <b>90</b> and <b>92</b>, respectively, which extend around annular walls <b>47</b><i>a </i>and <b>47</b><i>b</i>, respectively, of housing <b>20</b> on the inner surface <b>24</b><i>a </i>of base wall <b>24</b>. Annular lips <b>90</b> and <b>92</b> each include transverse connectors <b>94</b> and <b>96</b> which extend through elongate openings <b>24</b><i>b</i>, provided in base wall <b>24</b> of second housing member <b>20</b>, to outer annular walls <b>72</b> and <b>73</b>. Transverse connectors <b>94</b> and <b>96</b>, in combination with annular lips <b>90</b> and <b>92</b>, provide further anchoring of diaphragms <b>68</b> and <b>70</b> to housing member <b>20</b>.

Referring to FIGS. 5 and 8, a pair of motor noise dampeners <b>98</b> and <b>100</b> are provided, which are injection molded with or onto the inner surface <b>24</b><i>a </i>of base wall <b>24</b> of second housing member <b>20</b>. Dampeners <b>98</b> and <b>100</b> are positioned to align with motors <b>28</b> and <b>29</b> in the completed assembly when upper and lower housing members <b>19</b> and <b>20</b> are secured together. Dampeners <b>98</b> and <b>100</b> press against motors <b>28</b> and <b>29</b> when upper and lower housing members <b>19</b> and <b>20</b> are secured together and, therefore, dampen the noise from the motors. Preferably, dampeners <b>98</b> and <b>100</b> are injection molded with second housing member <b>20</b> and may be mechanically interlocked or chemically adhered to the base wall <b>24</b> of housing member <b>20</b>.

As best seen in FIG. 8, dampeners <b>98</b> and <b>100</b> are “dog bone” shaped with each dampener having circular ends <b>102</b>, <b>104</b> and a transverse elongate section <b>106</b> which extends between circular ends <b>102</b> and <b>104</b>. The shape of dampeners <b>98</b> and <b>100</b> may vary—the “dog bone” shape illustrated in the figures is just one example and not intended to limit the scope of protection. Preferably, base wall <b>24</b> includes a pair of recesses or depressions <b>108</b> on its inner surface <b>24</b><i>a </i>into which dampeners <b>98</b> and <b>100</b> are injected.

Depressions <b>108</b> may comprise channel shaped depressions <b>109</b> as shown in FIG. <b>9</b>. Alternatively, base wall <b>24</b> may include depressions <b>108</b>′, which comprise beveled grooves having reverse beveled sides <b>110</b> and <b>112</b> forming a reverse chamfer, which provides mechanical locking of the dampeners <b>98</b> and <b>100</b> to base wall <b>24</b> (FIG. <b>10</b>). It should be understood that where a beveled groove is provided on base wall <b>24</b>, dampeners <b>98</b> and <b>100</b> may be inserted into depression <b>108</b>′ using mechanical means rather than molding.

In yet another embodiment, base wall <b>24</b> may include a plurality of apertures or openings <b>114</b> which extend from the inner surface <b>24</b><i>a </i>to the outer surface <b>24</b><i>c </i>of base wall <b>24</b>. When dampeners <b>98</b> and <b>100</b> are injection molded onto the inner surface <b>24</b><i>a </i>of base wall <b>24</b> of second housing member <b>20</b> over apertures <b>114</b>, the gasket material forming the dampeners <b>98</b> and <b>100</b> extends through apertures <b>114</b> to outer surface <b>24</b><i>c </i>of base wall <b>24</b> and forms a plurality of leads or prongs <b>116</b> and enlarged ends <b>118</b>. In this manner, when the gasket material is cured, dampeners <b>98</b> and <b>100</b> are mechanically locked or anchored to base <b>24</b> by prongs <b>116</b> and enlarged ends <b>118</b>.

The gasket material forming boots or diaphragms <b>68</b> and <b>70</b> and motor pads <b>98</b> and <b>100</b> is preferably a thermoplastic elastomer, such as Kraton (TPE) G2705 which is available from GLS Corp., Kerry, Ill. Other suitable gasket materials are TPR (Thermoplastic Rubber) or TPU (Thermoplastic Urethane). As described previously, second housing member <b>20</b> may comprise a glass-filled polypropylene material or the like, in which case the gasket material forming the seals and dampeners will chemically bond and adhere to base wall <b>24</b>. Alternatively, the boots and diaphragms may be mechanically locked with base wall <b>24</b> in a similar manner to noise dampeners <b>98</b> and <b>100</b>.

Referring to FIGS. 15-17, base wall <b>24</b> may include a recess or depression <b>70</b><i>a</i>, <b>70</b><i>a</i>′ formed on upper surface <b>24</b><i>a </i>of base wall <b>24</b> into which the gasket material forming diaphragms <b>68</b> and <b>70</b> may be injection molded. Similar to depressions <b>108</b>, the depressions may comprise channel shaped-grooves (<b>70</b><i>a</i>) with beveled side walls to mechanically hold the diaphragm <b>68</b>, <b>70</b> on base wall <b>24</b>. Alternatively, base wall <b>24</b> may include a plurality of apertures <b>70</b><i>b </i>that extend through base wall <b>24</b> so that when the gasket material is injection molded onto base wall <b>24</b>, the gasket material flows through apertures <b>70</b><i>b </i>to form prongs <b>70</b><i>c </i>that extend through to lip <b>92</b> on the inner surface of base wall <b>24</b>. The recess, beveled groove, and the prongs mechanically lock or anchor diaphragms <b>68</b> and <b>70</b> to base wall <b>24</b>. When diaphragms <b>68</b> and <b>70</b> are mechanically locked to base wall <b>24</b>, the material of the housing members may comprise ABS or PBT.

When injection molding boots <b>68</b> and <b>70</b> and dampeners <b>98</b> and <b>100</b>, a hot runner system may be used. In hot runner systems a single injection point or multiple injection points may be provided which direct the gasket material to the molding locations of the diaphragms and dampeners. Each molding location may include a designated gate in which case the need for crossovers or feeders is eliminated. However, where the number of molding locations exceeds the number of gates, then cross-overs are needed. In the illustrated embodiment, the number of molded structures (<b>68</b>, <b>70</b>, <b>98</b>, <b>100</b>) exceeds the number of gates provided in the hot-runner system and, therefore, cross-overs <b>119</b><i>a </i>and <b>119</b><i>b </i>are needed to direct the flow of the gasket material between the adjoining molded structures. As best seen in FIG. 8, two crossovers <b>119</b><i>a </i>and <b>119</b><i>b </i>are provided to direct the flow of the gasket material either from boot <b>68</b>, <b>70</b> to dampener <b>98</b>, <b>100</b> or from dampener <b>98</b>, <b>100</b> to boot <b>68</b>, <b>70</b> depending on the location of the gate. As explained above, these cross overs <b>119</b><i>a </i>and <b>119</b><i>b </i>may be eliminated where the number of gates equals the number of molded structures. It can also be appreciated that a third cross-over is needed where only a single gate is provided in the hot-runner system.

Referring to FIG. 12, a second embodiment of the second housing member <b>120</b> is shown. Second housing member <b>120</b> is of similar construction to housing <b>20</b>, except that housing <b>120</b> further includes an integral gasket seal <b>121</b>, which extends around the perimeter of second housing <b>120</b> inwardly of an outward sidewall <b>125</b>. Similar to boots <b>68</b>, <b>70</b> and dampeners <b>98</b> and <b>100</b>, gasket seal <b>121</b> is preferably integrally molded with second housing <b>120</b>. As best seen in FIG. 14, the gasket material is injected and molded onto a landing or shoulder <b>125</b><i>a </i>of side wall <b>125</b> so that when second housing member <b>120</b> is secured to first housing member <b>19</b>, gasket seal <b>121</b> will seal the perimeter connection between the two housing members. Sidewall <b>125</b> includes an offset portion <b>125</b><i>b </i>which overlaps with an upwardly extending offset peripheral portion <b>22</b><i>b </i>of sidewall <b>22</b> of lower housing member <b>19</b> to provide a first outermost barrier to the elements. Preferably, side wall <b>22</b> of lower housing member <b>19</b> includes a horizontal offset <b>22</b><i>a </i>to allow a closer fit-up between the overlapping perimeters of sidewalls <b>125</b> and <b>22</b>. Again, integral gasket seal <b>121</b> may be molded separately from the other molded structures (<b>68</b>, <b>70</b>, <b>98</b>, <b>100</b>) in which case no cross-overs or feeders are required. Where the hot runner system includes fewer gates than there are molded structures, as described in reference to diaphragms <b>68</b> and <b>70</b> and dampeners <b>98</b> and <b>100</b>, cross-overs, however, are required to permit the flow of the gasket material from the respective gate to the several molded structures, including the gasket seal <b>121</b>.

In the illustrated embodiment, in FIGS. 13 and 14, cross-over <b>123</b> extends from diaphragm <b>70</b> to gasket seal <b>121</b>. Preferably, there are a plurality of cross-overs (<b>123</b>) between diaphragms <b>68</b> and <b>70</b> and the gasket seal <b>121</b> to assure that the gasket material flows along the entire perimeter of the second housing member <b>120</b> over the full length of seal <b>121</b>. Moreover, additional cross-overs <b>223</b><i>a </i>and <b>224</b><i>a </i>may extend between dampeners <b>98</b> and <b>100</b>, respectively, and gasket seal <b>121</b> to reduce the length of the flow path. It should be understood from the foregoing that the number of cross-overs depend on the number of gates and also depend on the hot runner system and the flow properties of the particular gasket material used.

In the illustrated embodiment, in FIG. 13, gasket seal <b>121</b> is molded with the planar, upper surface of shoulder <b>125</b><i>a. </i>However, as best seen in FIG. 14, shoulder <b>125</b><i>a </i>may include a depression <b>125</b><i>c </i>to increase the contact surface and thereby improves adhesion between gasket seal <b>121</b> and second housing member <b>120</b>.

Referring to FIG. 12, a third weather seal <b>221</b> may be provided around the distal end of collar <b>59</b> of socket member <b>56</b>. Seal <b>221</b> is similarly preferably injection molded with second housing member <b>20</b>. Gasket seal <b>221</b> abuts a shoulder <b>65</b><i>a </i>of boss structure <b>65</b> and therefore provides a seal for the ball and socket connection between mirror backing plate <b>14</b> and second housing member <b>120</b> (FIG. <b>6</b>). Moreover, the gasket material forming seal <b>221</b> may be directed to collar <b>59</b> by cross-overs <b>223</b><i>b </i>and <b>224</b><i>b </i>extending from dampeners <b>98</b> and <b>100</b>, respectively, to the distal end of collar <b>59</b>.

In addition to providing an improved seal, integral gasket seal <b>121</b> reduces the relative play between the upper and lower housing members <b>19</b> and <b>120</b>. Moreover, by having an integral gasket seal, upper and lower housing members <b>19</b> and <b>120</b> may be quickly assembled, disassembled, and re-assembled without the attendant problems and costs associated with die cut gaskets. The integral diaphragms similarly provide enhanced seals and, like the integral motor dampeners and gasket seal, reduce the assembly and disassemble time.

Furthermore while several forms of the invention have been shown and described, other forms will now be apparent to those skilled in the art. For instance, some or all the molded structures (<b>68</b>, <b>70</b>, <b>98</b>, <b>100</b>, <b>121</b>, <b>221</b>) may be chemically bonded to the respective surfaces on second housing members <b>20</b>, <b>120</b>. Chemically bonding is achieved by selecting the material of the housing and gasket material such that when the gasket material is in a semi-molten state and is placed or flowed onto the housing, chemical adhesion between the two polymers forming the housing and the gasket material occurs. As described, housing <b>20</b>, <b>120</b> may comprise glass-filled polypropylene, and the gasket material may comprise a thermoplastic elastic family material. Moreover, the shape of the boots, motor pads and gasket seal may vary. The embodiments of the invention shown in the drawings and described above are not intended to limit the scope of the invention which is defined by the claims which follow.

The embodiments of the invention in which we claim exclusive property or privilege are defined as: